I got my '96 SP500 back from the shop last Friday. I had the HO kit installed that I got from Bill Osborn along with the green clutch spring and K&N filter. MAN!! What a difference! This thing will absolutely FLY now! It'll spin the h@ll out of the 26" Mudrunners on dry ground. I can tell alot of difference in the clutch setup, too. From 0-30mph is about like a dirtbike...and after reading a few posts in here, I thought I wouldn't gain (and might even lose) some top-end. Well, that's definitely not the case. Whether it's the spring or the engine mods I couldn't really tell, but I gained about 5 mph top-end.
The only problem I have is it seems to run a little rich on first start-up. But the mechanic jetted the new carb for a stock filter...he said I might have to re-jet. Anyone got any suggestions?
Anyway, I am very, very pleased with how this overhaul has gone.

 

Hey Todd, All said and done, how much do you have into the new setup?? How many miles we're on the old SP before the over haul??

Thanks

 

All totaled, I have $650 in the rebuild. That's $350 for parts (which is a steal b/c the carb lists for over $400) and $300 to put all of it in. As far as the miles, I can't really tell you. The speedo stayed unhooked for about a year, but the odometer says 2000.

Just a side note: I was very impressed with the condition of the orginal cam. I service it regularly, but failed to see near the wear I had expected. I guess that synthetic oil really does work.